Document Emy5V6YwDkmKr043m1X6Z3xR4

ABD00311805 SAFETY - C. M. Markerson/J. V. Uptain First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Injuries bv Department Jan. 1 2 3 2 0 Fiscal Y.T.D. 1995 8 3 11 2 0 Y.T.D. 1994 7 _2 9 1 1 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 12 03 25 00 00 <2. 3 11 0 5 3 1 2 _a 11 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 05 00 02 11 22 01 0. _0 3 11 6 0 1 2 1 0 11 Non-Occupational Injuries Lost Workday Cases Days Lost Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases 00 00 00 00 00 5 124 0 0 0 Safety Record Last lost time injury Days since Employee hours since - 01/22/94 374 460,830 On January 31, 1995, the employees of the Aberdeen Plant completed 374 days with no lost time injury. The main topic for the plant safety meetings during the month was "Medical and Exposure Records Access". ABD00311806 SAFETY - Continued Routine dosimetry results for the month were: Chemical < PEL Number Percent VCM Lead Total Particulates 55 94.8 6 100.0 2 100.0 > PEL Number Percent 3 5.2 00 00 One of the three VCM overexposures was without benefit of respiratory protection. Monthly Injury Summary Iniurv Class FA RWC RWC Department I&E Yard Maintenance Description Back strain. Muscle strain, left side. Contusion, middle right back ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) TOTAL INJURIES OSHA RECORDABLE ABD00311807 COST VARIANCES - J. B. Autrey Variable Costs Product Jan.. 95 Variance. $M Efficiency Price Total PVC Flexible Compound Plasticizer Total < 184.5> 31.9 81.6 < 71.0> <3060.9> < 418.3> < 197.5> <3676.7> <3245.4> < 386.4> < 115.9> <3747.7> PVC Resin The unfavorable efficiency variance for PVC was due to an un favorable VCM efficiency on a total production basis. Higher than budgeted VCM prices continue to be the cause of the majority of the negative variable cost variance. Flexible Compound and Plasticizer The major contributors to the negative Compound price variance continue to be higher than budgeted resin transfer prices and antimony oxide prices, and is offset by favorable aluminum tri hydrate prices. The negative Plasticizer price variance is due to phthalic anhydride and alcohol pricing. Manor Price Variances Variance - $M VCM m Resin to Compound m Antimony Oxide m Aluminum Trihydrate Filler m Phthalic Anhydride Alcohol <3185.3> < 272.7> < 103.9> 61.7 < 89.7> < 108.5> VINYL - J. D. Olson Safety The Vinyl Department had no injuries in January. The monthly safety meetings were held on shift. General January's production of 51.9MM is a new monthly production record surpassing the previous mark of 49.8MM set in December, 1994. r ABD00311808 VINYL - Continued General - continued Jan. - Production, MM Lbs. - Reactor Stream Factor, % - Resin Quality, % Prime - VCM Efficiency, Lbs./Lb. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % % 51.9 97.1 97.9 1.0447 1674 100.0 1148.0 37.0 92.7 96.3 Reactor Downtime m Operational downtime (recovery scheduling conflicts). mm Mechanical (Mechanical replacement, recovery system repairs) Drver Downtime m Operational downtime (cleaning, product changes, and centrifuge plugs). mm Mechanical downtime mm Reactor limited production YTD 341.4 95.6 97.1 1.0381 1588 94.0 7663.0 35.6 95.4 97.2 Hours 128 85 Hours 51 70 151 COMPOUND- S. C.Hillman Safety The Compound Department had no OSHA recordable injury during the month. General Compound prime production in January totaled 7.4MM pounds. Plasticizer production totaled 1.8MM pounds in January. was completed on the first DCS training. Testing ABD00311809 COMPOUND - Continued Comoound Production Operating Davs Production M (Lbs). Month Ayq,/Day Fiscal Y.T.D. Line I 31 Line III 31 Line V 31 Total % Prime Capacity Utilization Factor 1880 4215 1265 7360 97.5 70.3 61 136 41 237 13592 28483 8398 50173 97.1 68.6 The utilization factor basis was changed for January. Downtime Hours L_ine__I_ - Product Changes - Miscellaneous Maintenance - Quality - Miscellaneous 112 32 5 21 Line__IIX - Product Changes - Miscellaneous Maintenance - Miscellaneous 57 32 5 Line V - Product Changes - Miscellaneous Maintenance - Quality - Miscellaneous 53 22 16 9 Operating Davs Production (M Lbs.) Month Avg,/Day Fiscal Y.T.D Plasticizer 31 % Prime Capacity Utilization Factor 1787 79.2 69.4 58 12711 84.6 91.1 ABD00311810 ENGINEERING - J. E. Nickerson OSHA Process Safety HAZQ.ES The New Module HAZOP was completed. Work began on the SA Module HAZOP. Completion is scheduled for March, 1995. New Module Charge Water System Upgrade This project will install a new hot water charge pump and associated piping in the New Module. This will provide faster charges and allow simulanteous charge and rinse. Construction is mostly complete. Final tie-ins and programming were completed for startup during the DCS shutdown in late January. We will optimize rates and complete any required troubleshooting in February. Economy Surplus_Eower Conversion A plant electrical curtailment plan is being drafted for potential temporary reductions in power under the new contract. Design work is complete for a power monitoring system which is required with ESP. Contract negotiations with the Aberdeen Water and Light and TVA are in progress. Conversion to the new rate structure should be complete by March 20, with a chance for conversion in February. Recovery Compressor Addition for OldJModule The AFE has been approved and drafting for the mechanical design is underway. Activator Replacement_and.Resin Transfer Improvements The feeder is on order. Mechanical design work is in progress. Reactor 741 Larger Batch Trial The AFE has been approved. Mechanical design work for installation on reactor 741 has commenced. A radioactive materials license is pending. V-10 Coalescing Filter A coalescing filter to reduce moisture in the resin dryer transfer air will be installed. Air moisture problems have increased since the rental compressor was brought in. ABD00311811 ENGINEERING - Continued Plant Air Upgrade The silo aeration and blend tank mechanical design is nearly complete. Some piping has been installed. Compressor bid speci fications are in progress. ENVIRONMENTAL - K. G. Akins Water All wastewater discharge limitations were within permitted limits for the month of January. Air Mississippi's Title V air operating permit regulations became effective 1/28/95. The plant will have until 1/28/96 to sub mit a Title V air permit application. The emission inventory was essentially completed in January and work will now focus on regulatory analysis and operating flexibility. The NESHAPS Subpart V VCM valve survey was completed in late December and included a survey of all valves in VCM service. No leakers were found. Wastes There were no waste shipments in January. KEY ENVIRONMENTAL COMPLIANCE DATA MONTH FYTD Stormwater Outfall Excursions Wastewater Outfall Excursions Reportable NESHAP Excursions Reportable non-NESHAP Air Excursions CERCLA/SARA Reportable Incidents Other Reportable Incidents Citations and NOV's Received 0 1 1 0 0 0 0 0 2 1 0 0 0 0 ABD00311812 ENERGY CONSERVATION - J. A. Bodron A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU January. 1995 6.5% 6.9% 2491.0 156.2 Fiscal Y.T.D. 8.0% 7.9% 2441.8 1002.5 ABERDEEN ENERGY EFFICIENCY BTU/LB TOTAL PRODUCTION